Finite Element Analysis of a Brake Disc under Constant Mechanical Loading

A brake disc is one of the most critical components in modern vehicle’s brake systems; hence, thorough validation of its performances in the development process by simulations, rig and vehicle tests is essential. In this paper, a disc brake system under a constant braking torque is analyzed using finite element method, and the stress and strain in a rotating ventilated brake disc employed are studied comprehensively. From detailed examination of the stress distribution and the cyclic stress history, it is found that the maximum stress in the rotating brake disc under the constant mechanical loading only occurs at some specified locations; and the stress history is multiaxial and non-proportional. These findings will help, as guidelines, to develop suitable evaluation tools for the strength and the fatigue of the brake discs; to setup proper laboratory test procedures and equipment; and to design strong and durable brake discs. Furthermore, the stress and strain under various amplitudes of loading are analyzed, and a linear relationship between the maximum stress/strain and the amplitude of loading is established. Finally, two simplified finite element modeling methods to shorten the analysis time are evaluated.